Modular building structure

ABSTRACT

Disclosed herein is a modular building structure. The structure includes a modular building roof structure comprising the roof structure which includes a plurality of truss structures each having a top and a bottom and a pair of deck layers attached to and for transversely spanning the tops of the truss structures. The roof structure also includes an acoustical ceiling suspended along the bottoms of the truss structures. The building structure also includes a modular building floor structure which comprises a deck structure including an upper deck pan and a lower deck pan disposed opposite and adjacent each other to create a plurality of spaced apart support channels. In a preferred embodiment, the deck structure is oriented transverse to the support beams. The floor structure further includes a plurality of support beams for supporting the deck structure. Significantly, the deck and the acoustical ceiling define a return air plenum that provides for proper venting, distribution and circulation of air, including introduction of fresh air, throughout the modular structure. Advantageously, no separate ductwork or duct system is required with the use of the air plenum. Preferably, the structure is substantially non-combustible and mold-resistant.

BACKGROUND OF THE INVENTION

This invention relates generally to modular building systems, and moreparticularly to modular building roof and floor structures.

Modularly constructed building structures are advantageous in that theyprovide shelter from the elements in which a variety of activities canbe housed, and are relatively easily transported from one locale toanother. Moreover, such structures can typically be assembled instackable sections, or sections placed side-by-side (i.e., the sectionsare positioned adjacent each other), right on site after beingtransported. Modular building structures can be used for production ofsingle and multi-unit or multi-family homes, as well as apartments,condominiums, classrooms, general offices, medical facilities,commercial buildings and the like.

Many modular building structures are custom designed. However, buildingstructures can also be designed according to standard or pre-fabricatedbuilding templates as well. Today's modular building structures arecomputer-engineered to meet national building codes. They can beprecisely engineered for increased structural durability. High qualitycan be maintained by inspection during construction process. In oneconstruction example, a modular building structure is delivered to adesired site, after which individual modular structures or “modules” areassembled into an overall modular building structure.

In general, the metrics of building construction costs break out on aper square foot basis. It is a continuous goal to reduce theconstruction costs of the modular structures. To this end, it would bedesirable to provide a modular building structure that, while meetingall applicable building codes and other standards, is simpler toconstruct than known modular building structures. For example, abuilding structure comprising fewer pieces, parts or other components inits construction is desirable. Similarly, material selection for suchmodular building structures is key, in that the material type andplacement can result in a building structure of having a greater usefullife and durability.

It would also be desirable to use stronger and more durable modules orsubstructures in making the overall modular building structure. This canlead to a decrease in the number of supports or braces in a given area,thereby reducing modular building structure costs on a square footbasis. Advantageously, the mating of various components can provideincreased strength, which, in conjunction with the reduction in thenumber of support structures, reduces overall modular weight, inaddition to construction and transportation costs.

Further, in the modular building structure industry, there areincreasing requirements aimed at improving the structure resistance tomold and combustion. Accordingly, it would be desirable to provide amodular building structure that increases the used of stainless steelmaterials in order to achieve these desired ends.

BRIEF SUMMARY OF THE INVENTION

An inventive modular building structure is disclosed herein. In oneembodiment, a modular building roof structure in combination with anacoustical ceiling is disclosed, the combination comprising a modularbuilding roof structure comprising a plurality of truss structures eachhaving a top and a bottom; a pair of deck layers attached to and fortransversely spanning the tops of the truss structures; and anacoustical ceiling suspended along the bottoms of the truss structures;wherein the deck and the acoustical ceiling define a return air plenum.

In another embodiment, a modular building floor structure is disclosedcomprising a deck structure including an upper deck pan and a lower deckpan disposed opposite and adjacent each other to create a plurality ofspaced apart support channels; and a plurality of support beams forsupporting the deck structure. In a preferred embodiment, the deckstructure is oriented transverse to the support beams.

And in another embodiment, a modular building structure is disclosedcomprising a modular building roof structure in combination with asuspended acoustical ceiling system, the combination comprising amodular building roof structure comprising a plurality of trussstructures each having a top and a bottom; a pair of deck layersattached to and for transversely. spanning the tops of the trussstructures; and an acoustical ceiling suspended along the bottoms of thetruss structures; and a modular building floor structure comprising adeck structure including an upper deck pan and a lower deck pan disposedopposite and adjacent each other to create a plurality of spaced apartsupport channels; and a plurality of support beams for supporting thedeck structure; wherein the deck and the acoustical ceiling define areturn air plenum. In a preferred embodiment, the deck structure isoriented transverse to the support beams.

Other objects, aspects, and advantages of the invention will be apparentupon a thorough reading of the detailed description below along with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are disclosed with reference to theaccompanying drawings and are for illustrative purposes only. Theinvention is not limited in its application to the details ofconstruction or the arrangement of the components illustrated in thedrawings. The invention is capable of other embodiments or of beingpracticed or carried out in other various ways. Like reference numeralsare used to indicate like components.

FIG. 1 is a perspective view of a group of modular building structuresaccording to one aspect of the present invention;

FIG. 2 is a top plan view of a plurality of modular building structures;

FIG. 3A is a cut-away partial perspective view of the modular buildingstructure taken along line 3A-3A of FIG. 1;

FIG. 3B is an alternative embodiment of the perspective view of themodular building structure of FIG. 3A showing the use of an I-beam dualdeck pan floor construction;

FIG. 3C is a is an alternative embodiment of the perspective view of themodular building structure of FIG. 3A showing the use of an I-beam dualdeck pan floor construction in addition to a dual deck pan roofconstruction;

FIG. 4 is a cross-sectional view of the modular building structure takenalong line 4-4 of FIG. 1;

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4;

FIG. 6 is an enlarged sectional view taken along line 6-6 of FIG. 4showing a portion of the modular building roof structure;

FIG. 7 is an enlarged sectional view taken along line 7-7 of FIG. 4showing a portion of the modular building floor structure;

FIG. 8 is an enlarged cross-sectional view taken along line 8-8 of FIG.4 showing a portion of the modular building roof structure with a returnair plenum according to one aspect of the present invention;

FIG. 9A is an enlarged cross-sectional view taken along line 9A-9A ofFIG. 7 showing the pair of deck pans according to one aspect of thepresent invention;

FIG. 9B is an alternative embodiment of the pair of deck pans shown in aspaced apart arrangement; and

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a perspective view of a group of modular buildingstructures 10 are shown. The group includes any number (as indicated bythe hashed lines) of individual structures 12 a-d, such as modularstructure 12 b, which can be aligned or positioned in a repeatablefashion as shown according to the space requirements for the particularapplication. In the embodiment shown, the modular units include roofstructures 18 having a pitch with an apex along centerline 21. In selectapplications, the roof structures 18 can be constructed in a flattenedmanner to the extent that modular units can be stacked to facilitatetransportation of multiple units to specific locations. In general, ifstacking of the modular structures is desired, as is contemplated inmulti-story applications of the present invention, the roof structurepitch is typically reduced or eliminated altogether. Applications formodular building structures such as that shown in FIG. 1 include office,educational, health or medical, laboratory space, residential, and lightmanufacturing, among others. In a typical construction, each modularbuilding unit can include such features as doors 14 and windows 16,replicating features found in permanent building structures. Eachindividual structure or module 12 a-d has in and of itself the requisiteelements to resist the lateral loads due to winds and earthquakeconditions. Advantageously, the lateral loads resistance or lateral loadbearing characteristics are also additive. That is, when the structuresare placed next to one another side to side, the lateral load resistanceis additive. Therefore, providing one structure with x lateral loadresistance level next to another structure with y lateral loadresistance, an additive effect of x+y total lateral load resistance willbe achieved. The combined structure will be able to withstand thecombined individual additive lateral loads. When a plurality of themodular buildings are placed laterally together to create a modularbuilding group having a total lateral load bearing characteristic, thetotal lateral load bearing characteristic is additive from theindividual modular building lateral load bearing characteristics.

FIG. 2 is a top plan view of a plurality 20 of modular buildingstructures 22 a-e. In structure 22 d, a portion of the modular buildingstructure interior 24 is shown along with several interior elements 26(e.g., a sink, a toilet, a door, etc.). In the embodiment shown, themodular structures are shown positioned in side-by-side or adjacentfashion, however, it is contemplated that the modular units can bearranged or positioned in ways that can vary to convenience. Inaddition, the modular units are scaleable, both in size and number,depending on the application at hand.

FIG. 3A is a cut-away partial perspective view of modular buildingstructure 10 taken along line 3A-3A of FIG. 1. In FIG. 3A, variouscomponents and layers are illustrated in cutaway fashion to facilitateunderstanding of the invention. FIG. 4 is a cross-sectional view of themodular building structure 10 taken along line 4-4 of FIG. 1.

Referring to FIGS. 3A and 4, modular building structure 10 includes amodular building roof structure 32 and a modular building floorstructure 34. The modular building roof structure 32 includes aplurality of longitudinal, open web trusses 36. Each of the plurality oftrusses 36 has a first end 38 (FIG. 3A) and a second end 40 opposite thefirst end. Tubular columns 42 may be positioned at the first and secondends 38, 40 of the trusses 36 for supporting the trusses. The ends 38,40of the trusses 36 may also be supported by a two-dimensional frame inorder to reduce the number of columns required Each truss or trussstructure 36 includes longitudinally disposed supporting beams 46 and 48connected in overlapping or “sandwiched” fashion using tension andcompression members 50. The beams 46 and 48 are, in the embodimentshown, comprised of individual support beam members 46 a,b and 48 a,b. Adeck 52 is attached to and spans the tops 35 of the truss structures 36.In one embodiment, the deck is roll-formed and can be made of steel. Asuspended acoustical ceiling 54, which may be of a ceiling tile variety,can be suspended along the bottoms 39 of the trusses and in this fashionbe combined with the modular roof structure 32.

Significantly, the deck 52 and the suspended acoustical ceiling define areturn air plenum space 56. The return air plenum space 56, incombination with any physical vents, provides for proper venting,distribution and circulation of air, including introduction of freshair, throughout the modular structure. As a result of the presentstructural arrangement, no separate ductwork or duct system is required,which provides savings in the manufacture, both in terms of material andlabor costs, of the modular building structure of the present invention.Preferably, at least one of the plurality of longitudinal, open webtrusses, the plurality of tubular columns, and the roll-formed deck canbe constructed of steel, and in a preferred embodiment, the deck 52 issubstantially covered with a mold-resistant foam insulation material 57.Accordingly, the modular building roof structure 32 can be described assubstantially non-combustible and substantially mold-resistant.

The modular building structure 10 further includes a modular buildingfloor structure 34 which is joined or connected to the roof structure 32as shown via columns 42. The floor structure 34 includes a single layerdeck structure 58. A plurality of longitudinal main support beams 60,also called “Z purlins”, are connected to the deck pans and are orientedtransverse to the length of the floor structure. Advantageously, thepresent invention provides for the ability of the support beams to bepositioned in spaced apart fashion, typically about 12 to 14 feet apartover the entire length of the modular building unit. End support beamsor “I-beams” 62 are utilized at the outer region of the floor structure.In one embodiment, a decking surface 64, typically of a plywood, cementboard, poured concrete or combination type, can be connected to,positioned or laid over, or otherwise formed over, the pair of deckpans. As an additional feature, wheels 66 can be provided to improve themobility of the modular unit.

FIG. 3B is an embodiment of the perspective view of the modular buildingstructure 10 of FIG. 3A showing an improvement through the use of anI-beam dual deck pan floor construction 61 for use in the overall floorstructure 34. The z purlins of FIG. 3A are replaced here on each edgewith an I beam 63 that runs the length of the building 10. Although notshown, the opposite edge would mirror the edge shown to complete thefloor structure. Advantageously, the result is the use of fewer heavymetal construction components. Specifically, the plurality of transversez-purlins are replaced by only two I beams that run the length of module10. The benefits conferred by I-beams 63 include: reduction ofconstruction costs of module 10, reduced overall weight, and reducedmaterial (which reduced material transportation costs), among others. Apair of deck pans 65 is utilized in order increase strength. The pairare oriented to be transverse to the length of the I-beams such that theribs of the pair run the width of module 10. It is the increasedstrength of the transverse deck pan pair 65 that helps permit the use ofthe longitudinal I beams 63, and at longer intervals between beams, toreduce the number of support beams required overall. The traverse dualdecking 65 and the lengthwise I-beams 63 together make up the I-beamdual deck pan floor construction 61 for use in the overall floorstructure 34.

FIG. 3C is a is an alternative embodiment of the perspective view of themodular building structure of FIG. 3B showing the use of an I-beam dualdeck pan floor construction 61 in addition to a dual deck pan roofconstruction 71. By “dual deck pan roof construction” it is meant thatthe roof construction comprises two main trusses 73, 75 along with apair of deck pans 77, 79. Again, the dual pans provide additionalstructural support when compared to a single deck pan arrangement. Theincreased strength permits the weight of the roof to be supported by fewtrusses, as shown, trusses 73, 75, without deleterious effects such asbuckling or significant bending. The benefits conferred by the roofstructure shown include: reduction of construction costs, reducedoverall weight, and reduced material (which reduce materialtransportation costs), among others.

FIG. 6 is an enlarged sectional view taken along line 6-6 of FIG. 4showing a portion of the modular building roof structure 32. Supportmember 46 b and 48 b are connected via tension and compression members50. Decking 52 is attached at its lower surface 68 to the top of truss36, and specifically as shown to member 46 b. 1.5″ deck is one materialthat is suitable for use in the present invention. Acoustical ceiling54, which is typically made of an insulation material, is attached atits upper surface 70 to decking 52 through the use of suspension wires.The roof structure and ceiling create combination 37. Decking 52 andceiling 54 create return air plenum 56. Again, as a result of thepresent structural arrangement, no separate return air ductwork or ductsystem is required, the modular building structure of the presentinvention can be constructed for less money with fewer materials andwith a less complicated air distribution system. Truss 36 is supportedat its end by column 42. Various supports 72 include, as shown, 2×2 or2×4 wood supports members. A roofing material 74 (e.g., 0.060 in. EPDM)can be laid or applied to the upper surface of the foam insulation 57.The roofing material can be secured, for example, to trim 76. Supports72 are connected and secured to the truss 36 via a track 78, such as a“C” track, and covered by the roofing material 74. Other paneling 80 andtrim elements 82 can be added to complete the exterior of the roofingstructure as desired.

FIG. 8 is an enlarged cross-sectional view taken along line 8-8 of FIG.4 showing a portion of modular building roof structure 32 with plenum56. Space or plenum 56 runs, in a preferred embodiment, substantiallythe entire length of the modular building roof structure. Again, in aknown fashion, the plenum is defined by the deck 52 at its upperboundary and the ceiling insulation material 54 on its lower boundary,as well as, by thermal insulation material 76 on its ends. The deck andceiling are connected by truss 36.

Referring to FIG. 5, a cross-sectional view taken along line 5-5 of FIG.4 is shown. As can be seen, a portion of the modular building structureis shown, illustrating several basic structural members. These membersinclude tubular members 42, “C” beams 44, which, in conjunction withstud members 45 serve to provide the requisite support for the trussesand connects the roof structure with the floor structure of the modularbuilding unit. Also, these members eliminate the need for intermediatesupport or support members within the overall modular buildingstructure. Exterior panels 47 are also included to protect the exteriorsurface of the modular building structure.

FIG. 7 is an enlarged sectional view taken along line 7-7 of FIG. 4showing a portion of the modular building floor structure 34. Supportbeams, such as I-beam 62 and Z-purlins 60 which are shown in exemplaryfashion, are used to support the deck pan 58 (with I-beams being used intransverse fashion when supporting dual layer deck pans). Again, foaminsulation 82, paneling 84 and trim 86 are used to provide protectionand buttress the support beams. Stud 88, preferably made of steel,provides the support necessary for the dual pans 58 to withstand thestresses imposed thereon. A steel strap 89 is shown for use insupporting insulation (not shown) which can be inserted or placed inspace 93 located above the strap. The strap runs through center punches91 a-b (also called eyelits) in I-beam 62 and Z-beam 60.

FIG. 9A is an enlarged cross-sectional view taken along line 9A-9A ofFIG. 7 showing deck structure pair 65 of deck pans. In one embodiment,1.5″ deck is one material that is suitable for use in the presentinvention, although other materials are possible and contemplated. Morespecifically, an upper deck pan 90 and a lower deck pan 92 arepositioned in opposing adjacent fashion to create the deck support. Thepositioning of the pans 90, 92 create support channels 94, spaced apartby regions 96 in which the pans contact or substantially contact eachother. One manner of accomplishing this arrangement is to take a firstrolled, corrugated deck pan, and position it in opposing fashion with asimilar, if not identical, second deck pan. The arrangement illustratedpromotes maximum strength and rigidity for the modular floor structure,while minimizing the need for additional or unnecessary floor structuresupport members. Additionally, bending or other deflection of the floorstructure is also minimized. As a result, the deck structure is capableof supporting a greater load than each of one of the pair of deck pansindividually. Also, the deck structure has a combined deflection levelthat is less than an individual deflection level for each of the deckpans individually for a given load. Advantageously, the strengtheningcan be accomplished using materials, such as those described herein,that are common in the modular building industry. Moreover, it iscontemplated to add or insert materials into channels 94, with theinsertion of said additional materials adding to the strength of deckstructure pair 58.

FIG. 9B is an alternative embodiment of the pair of deck pans 90, 92shown in a adjacent and opposed relationship with a spaced apartarrangement to create gaps 95. This arrangement can be used on the roofstructure in addition to the floor structure of the present invention.In the embodiment shown, spacers 97 are inserted into gaps 95 to providea separation between deck pan 90 and pan 92, and more specifically, toseparate deck pan interior surfaces 99, 101. Here, in regions 103, thedeck pans contact spacers rather than the opposing deck pans directly.Significantly, spacers 97 provide for enhanced load distribution for agiven load. Resultantly, when compared to a single layer deck pan, andeven some dual deck pan arrangmenets, for steel deck pans of a givengauge, a greater load can be distributed, and alternatively, for a givenload, the embodiment of FIG. 9B permits the use of a lighter gaugesteel.

While the present invention has been described in terms of the preferredembodiment, it is recognized that equivalents, alternatives, andmodifications, aside from those expressly stated, are possible andwithin the scope of the appending claims.

1. A modular building roof structure in combination with an acousticalceiling, the combination comprising: a modular building roof structurecomprising: a plurality of truss structures each having a top and abottom; a pair of deck layers attached to and for transversely spanningthe tops of the truss structures; and an acoustical ceiling suspendedalong the bottoms of the truss structures; wherein the deck and theacoustical ceiling define a return air plenum.
 2. The combination ofclaim 1 wherein the trusses further comprise a plurality oflongitudinally disposed supporting beams connected in overlappingrelationship to a plurality of tension and compression members such thatthe trusses form a longitudinal, open web truss structure.
 3. Thecombination of claim 1 wherein the pair of deck layers is roll-formed.4. The combination of claim 1 wherein the pair of deck layers iscorrugated.
 5. The combination of claim 1 wherein the pair of decklayers is constructed of steel.
 6. The combination of claim 1 whereinthe modular building roof structure is at least one of substantiallynon-combustible and substantially mold-resistant.
 7. The combination ofclaim 1 further wherein at least one of the plurality of longitudinal,open web trusses, the plurality of tubular columns, and the roll-formeddeck comprise steel.
 8. A modular building floor structure comprising: adeck structure including an upper deck pan and a lower deck pan disposedopposite and adjacent to each other to create a plurality of spacedapart support channels; and a plurality of support beams for supportingthe deck structure; wherein the deck structure is oriented transverse tothe support beams.
 9. The modular building floor structure of claim 8further comprising a decking surface laid over the pair of deck pans.10. The modular building floor structure of claim 9 wherein the deckingsurface includes plywood and wherein the plywood is supported at leastin part by the support channels.
 11. The modular building floorstructure of claim 8 wherein the decking surface includes cement boardand wherein the cement board is supported at least in part by the spacedapart support channels.
 12. The modular building floor structure ofclaim 8 wherein the decking surface includes poured concrete and whereinthe concrete is supported at least in part by the support channels. 13.The modular building floor structure of claim 8 wherein at least one ofthe upper and lower deck pans is corrugated.
 14. The modular buildingfloor structure of claim 8 wherein the deck structure is capable ofsupporting a greater load than each of one of the pair of deck pansindividually.
 15. The modular building floor structure of claim 8wherein the deck structure has a combined deflection level that is lessthan an individual deflection level for each of the deck pansindividually for a given load.
 16. The modular building floor structureof claim 8 wherein the support members comprise at least one I-beam. 17.The modular building floor structure of claim 16 wherein the supportmembers comprise two I-beams.
 18. The modular building floor structureof claim 8 wherein the plurality of main support beams are spaced apartin intervals that are in a range of about 12 to about 14 feet.
 19. Amodular building structure comprising: a modular building roof structurein combination with a suspended acoustical ceiling system, thecombination comprising: a modular building roof structure comprising: aplurality of truss structures each having a top and a bottom; a pair ofdeck layers attached to and for transversely spanning the tops of thetruss structures; and an acoustical ceiling suspended along the bottomsof the truss structures; and a modular building floor structurecomprising: a deck structure including an upper deck pan and a lowerdeck pan disposed opposite and adjacent each other to create a pluralityof spaced apart support channels; and a plurality of support beams forsupporting the deck structure; wherein the deck and the acousticalceiling define a return air plenum; and wherein the deck structure isoriented transverse to the support beams.
 20. The modular buildingstructure of claim 19 wherein the upper deck pan and the lower deck panare separated to create a plurality of deck gaps, and further includinga plurality of spacers inserted into the plurality of deck gaps.
 21. Themodular building structure of claim 19 further including insertingsupport materials into the plurality of spaced apart support channelsfor increasing the support strength of the deck structure.
 22. Themodular building structure of claim 19 wherein each modular building hasa lateral load bearing characteristic, and that when a plurality of themodular buildings are placed laterally together to create a modularbuilding group having a total lateral load bearing characteristic, thetotal lateral load bearing characteristic is additive from theindividual modular building lateral load bearing characteristics. 23.The modular building structure of claim 19 wherein the pair of decklayers are separated to create a plurality of deck gaps, and furtherincluding a plurality of spacers inserted into the plurality of deckgaps.